■IPLACEX

NATIONAL TECHNOLOGY

Industrial networks
Exam

Student Rut Cristian Alarcón Saldías

Teacher 16.825.656-6
Course Iván Granados Lizama
Career Industrial networks
Instrumentation and
industrial control technician
07/05/2021
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam
Index

1. INTRODUCTION

1) INDUCTION

2) AIM

II. DEVELOPMENT 4

1) INTERCONNECT THE FIVE PRODUCTION LINES, 4

CONSIDERING ONE HMI SCREEN FOR EACH STATION AND INTEGRATING
COMMUNICATION WITH A PC STATION TO ACQUIRE AND MONITOR THE
PROCESS, LOCATED IN A ROOM 50 METERS FROM THE BOTTOMING
SECTION.

■IPLACEX.........................................................................................................................................1
NATIONAL TECHNOLOGY........................................................................................................1
Industrial networks..........................................................................................................................1
Exam............................................................................................................................................1
Index............................................................................................................................................2
YO. INTRODUCTION...........................................................................................................3
1) INDUCTION................................................................................................................3
2) AIM...............................................................................................................................4
11. DEVELOPMENT.........................................................................................................5
2) Organize the bottling section in a diagram, indicating the controllers of each
production line, the HMI screens and the PC......................................................................7
3) Make a request with the necessary tools.......................................................................7
for this task...........................................................................................................................7
"IPLACEX....................................................................................................................................10
6) Hierarchize the structure of the communication protocols you have chosen for the
section intercom solution...................................................................................................11
III. CONCLUSION................................................................................................................12
III.
 "IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam

YO. INTRODUCTION
1) INDUCTION
A soft drink company wants to update the bottling section of lemon and orange juice bottles,
because although they have a correct procedure, each line works independently with its controller,
sensors and actuators. The bottling section is made up of five production lines.
The process in each production line is as follows.
The automated station has three conveyor belts, two filling machines (one for each soft drink), one
capping machine, three retention systems and two pushing or transport systems.
As can be seen, the empty bottles arrive from the left side via the conveyor belts. In each filling
area, there is an optical sensor that detects the bottles that pass and when it reaches four, it
activates a retention mechanism to be able to fill the bottles without mishaps. Furthermore, at the
end of each filling station there is a transport mechanism that allows the bottles from both filling
stations to be unified on a single conveyor belt. To control this system there is another optical
sensor that detects the number of bottles that reach the end of the belt and when it reaches four, it
pushes them to the next belt.
Once the bottles are together, in rows of two, they are corked. Again there is a retention
mechanism to be able to carry it out. The same system is used as for filling: an optical sensor
detects the bottles that pass and when it reaches four, it activates the retention and proceeds to
capping.
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam
2) AIM

The objective of this work is to comply with the request of the engineering
department, which has the following requirements:

a) Interconnect the five production lines, consider an HMI screen for each
station and must integrate communication with a PC station for the
acquisition and monitoring of the process, located in a room 50 meters
from the bottling section.

b) Organize the bottling section in a diagram, indicating the controllers of

each production line, the HMI screens and the PC.

c) make a request with the necessary tools for said task.

d) Design the necessary topology for the project's interconnection solution

(justify the choice of network topology).

e) Find the communication protocol that satisfies the requirements (Justify

the choice of industrial communication protocol(s).

f) Hierarchize the structure of the communication protocols you have

chosen for the section intercom solution.
 "IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam
11. DEVELOPMENT

1) Interconnect the five production lines, consider an HMI screen

for each station and must integrate communication with a PC
station for the acquisition and monitoring of the process, located
in a room 50 meters from the bottling section.
For the process of interconnecting the lines, the first thing we will do will be the
identification of the protocol necessary for the communication of the actuators and sensors
with the rest of the circuit, which will include HMI screens, PLC and a PC station.

In this project we will use an AS-I communication protocol, therefore each line will be
suitable with this communication protocol. In addition to AS-I, we will use a PROFIBUS DP
communication protocol, which will help us communicate the sensor and actuator layer.
With the higher levels of the communication pyramid, the transition from AS-I to PROFI
BUS will be carried out by a PLC with a PROFIBUS DP / AS-I gateway, which will make
the technology change possible.

According to the characteristics of the application and the maximum cost to be achieved, a
gradual combination of different industrial communication network systems such as
PROFIBUS and AS-Interface are the ideal open network conditions for industrial processes.

As far as actuators/sensors are concerned, the AS-Interface is the perfect data communication
system, as the binary data signals are transmitted via an extremely simple and low-cost data
bus, together with the power supply. of 24Vdc necessary to power said sensors and actuators.

PROFIBUS DP is the high-speed PROFIBUS solution. Its development was mainly

perfected for communication between automation systems and decentralized teams.
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam

HMI

HMI

HMI

HMI

HMI
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam

2) Organize the bottling section in a diagram, indicating the

controllers of each production line, the HMI screens and the
PC.

In the following diagram we can see how the project will be developed, the other lines
will communicate and be powered by the AS-I cable, each line having its own master and
other field modules, sensors and actuators already represented in this diagram.

CONTROL ROOM
PC ACQUISITION
AND SENSORS AND SENSORS AND SENSOR AND
MONITORING ACTUATOR FILLING ACTUATOR THRUST ACTUATOR PLUGGING
PROCESS SYSTEM

HMI
FIELD FIELD FIELD
TEACHER MODULE MODULE MODULE

FOUNTAIN
OF POWER

3) Make a request with the necessary tools

for this task.

- AS-i cable: it is an unshielded, non-twisted cable, it has two parallel conductors and
transmits both data and power to the slaves. Its external cover is yellow and is
characterized by its geometric shape, and was designed to avoid connection with
reverse polarity.

Profibus cable: These cables are specifically designed to provide communication between process
automation systems and distributed peripherals in cases where time is limited.
a decisive factor.
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam

- Profibus connectors: these connectors will be used to connect the cable to devices
where it is necessary to use Profibus technology.

- PC: we will use a desktop PC station to monitor the process from the control room.
This unit will also be used to purchase products, supplies, technologies, or any other
need for the project.

- HMI Screen: The Human-Machine Interface (HMI) is the interface between the
process and the operator; It is basically an operator's instrument panel. It is the main
tool used by line operators and supervisors to coordinate and control industrial and
manufacturing processes.

- PLC with PROFIBUS DP / AS-I gateway: these gateways will help us combine
profibus technology with AS-I technology, with integrated fieldbus interface, reliable
and fast data exchange with the sensor-actuator level, color screen for displaying the
status of all available AS-i slaves, convenient and simple configuration,
commissioning and diagnostics, quick configuration menu with intuitive operation. In
addition, a standard PLC will be used for each line.

- Power supply: reliably supplies power to connected modules, sensors and actuators.
They have high interference immunity and sufficient power reserves for e.g. For
example, to reliably compensate for short current peaks. In addition, they provide safe
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam

decoupling to prevent disturbances from the primary power supply, the compact
housing requires little space in the electrical cabinet. The high degree of energy
efficiency of the equipment saves energy costs and reduces the residual heat of the
electrical cabinet.

- Field modules: Decentralized AS-i modules with quick mounting technique connect
binary and analog sensors and actuators to the gateway or PLC via the AS-i interface.
The flat cable can be connected in three different directions. The upper and lower parts
are no longer assembled as before, using four screws, but are locked using a sliding
lock. This guarantees quick, tool-free assembly and high assembly security.

- Hand tools: some hand tools will be needed to help with the implementation of this
project, among the necessary tools are pliers, screwdrivers, wire strippers, knife, etc.
"IPLACEX
NATIONAL TECHNOLOGY INDUSTRIAL
NETWORKS
Cristian Alarcón S. Exam
4) Design the necessary topology for the project's interconnection
solution (justify the choice of network topology).
Due to the use of the AS-I communication protocol there are no limitations in terms of
topology, the slaves can be connected in Bus, Star, Ring, Branch and Tree.
The freedom of topologies allows each slave to be connected at the point closest to the
network, or at the most accessible, considerably facilitating the task of wiring and
installing sensors and actuators. In an AS-i network there are no conditions for the
placement of slaves on the bus, however, the total length of the cable can be a condition
since it should not exceed 100m. If a longer length is needed, extenders and repeaters
would have to be used.

Having said the above, we can say that in this project the “TREE” type typology will be
used.

5) Find the communication protocol that satisfies the

requirements (Justify the choice of industrial communication
protocol(s).

This project will be carried out by a combination of 2 communication protocols.

For the communication of sensors and actuators, the AS-I protocol will be used, which
was chosen for the facilities it provides for the development of any topology, the ease of
developing the wiring, it is an open protocol, it transmits data and power through it. wire.

For the communication of the PLC with the HMI and PC screens, the Profibus DP
communication protocol will be used. This protocol is chosen for the ease of
interconnection with the protocol through the PLC with a Profibus / AS-I gateway.

9
 "IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam
6) Hierarchize the structure of the communication protocols you
have chosen for the section intercom solution.
FIELD AND PROCESS LEVEL: This level will
include the AS-I communication protocol, in addition to

MANAGEMENT LEVEL: This level will include

the Profibus DP communication protocol, in addition
to the PC station, which will be responsible for
monitoring the process and the acquisition of products
or any needs that the project may have.

CONTROL LEVEL: This level will include the

Profibus DP communication protocol, in addition to the
PLC with platform for AS-I, and the HMI screen, which
will be responsible for controlling and monitoring the
process by the operators.

LEVEL OF SENSORS AND ACTUATORS: This

level will include the AS-I communication protocol,
this level also includes the sensors and actuators,
which are responsible for carrying out the actions of
the process.

the master PLCs, the field modules and the power supply,
which will be responsible for the control, distribution and
power supply of the sensors and actuators respectively.

III. CONCLUSION
To carry out this work, it can be concluded that the best way to implement communication
protocols is to look for the combination of 2 protocols, specifically the Profibus DP and AS-I
protocols.

Looking for a way to combine both technologies, a wide variety of PLC manufacturers with
gateways were found that allow the transition from Profibus technology to AS-I, in this way we
"IPLACEX INDUSTRIAL
NATIONAL TECHNOLOGY
NETWORKS
Cristian Alarcón S. Exam
can take advantage of the advantages of AS-I technology at the levels. lower parts of the
communication pyramid and bring those advantages to the other layers of the pyramid with
Profibus DP technology, and in this way we will be able to control the process both from the
field and from the control room.